Automotive wheel CNC (Computed Numerical Control) / Manual Dual Control Lathe

ABSTRACT

The present invention is a novel machine for repairing damaged wheel rims whereby the machine is a combination CNC and manual lathe configured of performing all of the required tasks for repairing damaged wheel rims in a single unit.

INDEX TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/387,047 filed Sep. 28, 2010, the disclosure ofwhich is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates to a method and device for repairing wheelrims, and more particularly, to a method and device for repairing therims of automobiles after the rims have been dented or bent out ofshape.

In accordance with one aspect of the present invention, there isprovided a machine useful for repairing the rims of wheels. The machinemay be used with wheels of any composition including, but not limited tometals, metal alloys, composites and the like. According to a furtheraspect of the present invention, a method is provided for repairing thewheel rims of motor vehicles.

BRIEF SUMMARY OF THE INVENTION

The present invention is a machine for refinishing of repairing ofdamaged wheel rims comprising: selective operability as a manual lathe,CNC lathe, or combinations thereof; a rotational wheel rim holdingspindle; a jaw for holding a wheel rim, said jaw having plurality ofangular surface features that further secure said wheel rim; set screwsimbedded in said jaw, wherein said set screws extend outward from aninterior channel formed in said jaw and are utilized to level a wheelrim held in said jaw; at least two platforms for supporting a tool post;wherein said tool post is movable along at least 2 of an x-axis, ay-axis, and a z-axis.

The machine spindle is rotatable by moving a wheel rim secured thereto.The tool post is rotational about on an axis and is moved manually, by acomputer controlled program, or combinations thereof. The machineselective operability in manual or CNC mode is performed while saidwheel rim remains in said spindle.

The machine has a large swing about the spindle relative to size of amachine frame.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of the machine.

FIG. 2 is a rear view of the machine.

FIG. 3 is a left-side view of the total machine.

FIG. 4 is a right-side view of the total machine.

FIG. 5 is a partial front view showing the available working toolvolume.

FIG. 6 is a view from the right side showing the available total toolvolume.

FIG. 7 is an expanded view of the assembly of item 30 demonstratingslide tables from a front view.

FIG. 8 is an assembly of item 30 demonstrating XZ slide views in a rightside view.

FIG. 9A demonstrates a typical working tool being an electric digitalprobe.

FIG. 9B demonstrates a typical working tool bit.

FIG. 9C demonstrates a typical working burnishing brush.

FIG. 9D demonstrates a typical working tool being a burnishing brush.

FIG. 10A demonstrates a front view of rotatable tool holders about acentral axis.

FIG. 10B is a top view of rotatable tool holders about a central axis.

FIG. 10C demonstrates rotatable tool holders showing a polishing brushrotatable on an assembly about a central axis.

FIG. 11 is an expanded front view of the assembly of item 50 showing thechuck and drive mechanism.

FIG. 12 is a cross section of FIG. 1 along section lines from FIG. 1.

FIG. 13 is an expanded view of the assembly drive motor and machine baseas viewed from the left side of the machine.

FIG. 14 is an expanded partial cut away front view of a jaw 51 holderwith leveling screws holding a wheel rim.

FIG. 15 is a front view of the jaw 51 holder for a wheel rim.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Machine lathe 10 as described herein references the total assembly. Themachine is formed of various subassemblies each numbered for the sake ofdescription. Headstock mechanism 50 acutely secures an article to bemachined in a desired position. Tool post mechanism 2 provides forguidance of various typical working tools, bits, probes and the likeused in the machining process. Sliding table mechanism 30 provides formovement of the entire tool post mechanism 2 in order to effectuatemachining with applicable working tools, bits, probes and the like. Themachine lathe 10 further includes a microcomputer system 8 wherebyautomated machining can be controlled. Microcomputer 8 is operativelyassociated with the various movements of tool post mechanism 2 and othersuch mechanisms to provide computer control machine lathing. Machinelathe 10 further encompasses at least one door 12 and at least onetransparent window 20 that slideably moves along safety door sliding rod13 and is secured into a fixed enclosed position with safety doorbracket 14. A light fixture 15 is installed on the interior of themachine such that light fixture 15 illuminates a working article whendoor 12 is in a closed position. Door 12 is secured into a closedposition by door latch 19. Machine envelope frame 7 is a welded steelframe and is secured to machine base 9. Machine base 9 and machineenvelope frame 7 support each of the component parts of machine lathe10. Machine base 9 has incorporated therein leveling devices 17 whichare adjustable such that machine lathe 10 can be leveled even if thesurface upon which machine lathe 10 is residing is not completelyleveled. As shown in FIG. 2 machine lathe 10 has incorporated thereon abase plate for which is removable and provides for internal access ofelectrical power supply and microcomputer assembly 8. As seen in FIG. 4a drive motor 61 is mounted on a motor mount 62 and interacts withheadstock 50 that holds an article to be machined such that tool post 2provides for interaction with the article to be machine lathed. FIG. 5is a front view showing the working space for machine lathe 10 in oneembodiment dimension A being the overall lathe bed is aprox 48 incheslong by 20 inches wide The floor size of machine is about 72″×48″.

Dimension C being lathe height is approximately 73 inches. Dimension Dis the tool clearance diameter being the maximum throw of approximately30 inches. Dimension Z is the lathe tool bed range of approximately 24inches. It has always been a problem in the wheel repair industry toobtain a lathe that is small in floor footprint but with a largediameter swing. Swing is the maximum diameter of the workpiece. Somelathes are designed with a gap between the bed rails that allow the partto swing below the bottom of the headstock. The reason for this is thatproduction machines increase length of machine with swing. This is aindustry norm. There are not many machines at all that have such a largeswing without removing the gap. The problem with a machine that has thepossibility of removing the gap is that this would only create a largerswing over a short distance along the bed. This would normally behelpful in working on a flat round plate of not more that a few incheswide. With a wheel in place in the jaws it would extend past where thegap was thus making the removal of the gap useless.

As per FIG. 5 the working space is a ratio of approximately 1:1 inworking area. in other words there is approximately 30 inches of swingover bed with about 30 inches of tool post travel. There is no need tohave a long bed for a relatively narrow wheel. However it is desiredthat the swing over bed to accommodate the larger wheels manufacturedtoday.

In keeping the bed length short and widening the swing over, a morerealistic and economical machine is created.

As seen in FIG. 7 the directional movement is effectuated as follows:Product piece 11 is a typical article in which machine lathing isdesired in one embodiment of the present invention article 11 is a wheelrim. Tool post assembly 2 holds a probe 31 or other typical workingtool, bit or other working tool or bit to be used in the lathingprocess. Barrel 32 is a steel barrel with set screws to lock probe inposition and secures probe 31 into position. A quick released toolretainer 33 is a fixed on top of tool mount 34 such that the entirety oftool post mechanism 2 is moved by table mechanism 30. Table mechanism 30is formed of a hand wheel 35 for the “X” slide whereby table mechanism30 is moved along an x axis by either the hand wheel 35 or the servomotor 46 attached to the other end of the ball screw 47. Table mechanism30 is further moved by x slide rail 37 that moves along x slide mountbar 36. Movement along the x axis is accomplished through rotationalmovement of hand wheel 35 when power is removed from servo motor 46.When servo motor 46 is powered up then said movement is created alongslides by motor 46 rotating ball screw 47. Z slide hand wheel 43 movesalong a z direction through corporation of a pinion gear 63 that runsalong manual z rack 42. Movement within z slide mount bar upper 44 and zslide rail upper 45 is initialized by rotation of z servo motor 39. Asused herein an x movement of the slide is relative movement That willrun parallel to the face of the automotive wheel 11. and is provided byx slide mount bar 36 and provides the desired motion. As used herein thez direction is provided by lead screw 41 that is supported by a pair oflead screw end mounts 40. The mechanism moves by virtue of interactionof z lead screw 41 with z slide mount bar 44 and z slide rail 45. Asseen in FIG. 8, the x direction of movement provides movement of toolpost assembly 2 mounted on table mechanism 30. Tool holder 33 is mountedon rotational plate 29 and fastened into position with fastening bolts70. Slide rail 37 connects to tool post assembly 2 by support 34 beingtool mount 34. In use an operator will open safety door 12 in order toaccess the working mechanisms of machine lathe 10. Article 11, in thisexample being non-limiting article 11 is an automotive wheel rim isattached to headstock 50. Headstock 50 is constructed and arranged as atruck and drive assembly with a chuckjaw or jaw 51 and a headstock shaft52 as best seen in FIG. 13. A t-bolt slot 53 allows for t-bolt 54 to beplaced therein. Bearing 55 is placed within bearing spacer column 56 andlocked into a fixed position through bearing retainer nut 57. Drivebelt58 interacts with electromagnetic clutch 59 and is moved by virtue ofconnection with motor pulley 65 rotational movement of motor 61 turnsmotor pulley 65 moving drivebelt 58 and subsequently turning tailstockpulley 66. The rotational movement imparted by rotational motion ofmotor 61 ultimately turns automotive wheel 11 in a rotational manner.The fixed rotational movement of automotive wheel rim 11 allows it to bemachined through any of the appropriate machine tools that willultimately contact automotive wheel 11 by virtue of movement of toolpost assembly 2.

In one embodiment, shown in FIGS. 14 and 15 headstock 50 supports achuck jaw 72. Chuck jaw 72 has a plurality of angular surface featuresthat further secure a wheel rim 11 while being machined on machine 10.Chuck jaw 72 has incorporated therein a plurality of set screws 73. Theset screws can be unscrewed outward from the surface of chuck jaw 72 inorder to provide a horizontal level to wheel rim 11.

CNC/Manual Abilities with Reference FIG. 7:

There are two independent methods of moving in and out in the Zdirection. This is a method that has not been done before. The lowerslides 68 will harness any movement created by hand wheel 43 withtransfer through a rack and gear 42 to create travel in a z directionalong 68 the lower z slide rail. This movement will in effect move thecomplete machine from that point up. The machine can then be movedmanually toward and away from the wheel 11. One level up there isanother set of set of z slide rails/upper 45 which is under power by zservo motor 39 with transfer through ball screw 41. As mentionedprevious, these methods of movement are in the same z direction and actindependently of each other.

With this in mind, we can now do two things as a result of this. One isthat as we don't need any homing in this machine as start values are setfor every new wheel on the machine, we can now use this to create bothmanual and cnc movement.

On the one hand the manual and CNC can work independent or in unisonwith each other. Should the brake 72 be in the locked position then justthe CNC would be working. Should the brake be unlocked then while thecnc is running a program (i.e. cutting a wheel) adjustments can be madeby the operator to cut just that little bit more, or less, in a specificarea on the wheel. This would be beneficial in the event that there is adeep gouge in a certain area of the wheel and be best to cut only deeperin that specific spot. the operator would very slowly move hand wheel 43in at that area and then begin moving it out after the CNC has passedthe bad spot.

Machine lathe 10 is uniquely configured to selectively operate as eithera CNC (Computed Numerical Control) lathe or a manual lathe. The CNC isused mainly for the correction of cosmetic damage to the face of a wheelrim.

There are certain wheels that are known to have a diamond polish, alsoknown as a machined finished. The side of the wheel rim (i.e. the sidevisible when mounted on a car), is originally factory cut to a certaingiven shape. The final cuts are then made with a diamond shaped insertso as leave a bright, bare metal, screw cut type look. This finish hasbecome popular on many of the wheels that are available today.

In the case that one of these wheels are cosmetically damaged, a lighttrim with the lathe on “CNC mode”, would be able to correct that.

Machine lathe 10 is used in manual mode to give the operator the abilityto hand finish or hand repair certain conditions on a wheel without theassistance of any motors or electrical assists.

A conventional, or off the shelf lathe is suited for many purposes andpossible jobs, a large machine with a large footprint to be able toaccept wheels in the sizes that are manufactured in present times today.

Machine 10 of the present invention is constructed and arranged toaccommodate the wheel sizes and shapes and instead of the wheels beingaccommodated by the machine, the machine 10 is built to accommodate thewheel. It is thus capable of doing large and small wheels and stillhaving a small footprint, thus reducing floor space needed.

It is an advantage for any wheel shop to have both a CNC lathe and afully manual lathe. In other words two separate machines are normallyneeded.

For ease of operation, machine 10 is combined into one within the newAutomotive wheel CNC (computed Numerical Control) lathe. This machine isnow capable of either being a complete CNC machine on the one hand, orwith the push of a button, it can convert to a fully manual machine onthe other.

The manual machines movement of tool post within its axis is initiatedby a human with the turning of hand wheels, that manually will movemethod of traverse (e.g. ball screws, lead screws or rack). This will inturn create movement of the desired tool post.

The chuck will be controlled by an on/off switch with speed selectionthat will be controlled manually by the operator of machine. Thus themachine will be controlled totally by operator.

The same movement can be created by a similar method on most CNCmachines, the manual turning of the hand wheel is transferred toelectrical methods of controlling the servo motors to move method oftraverse, (e.g. ball screws or rack) which will in turn move the toolpost. In other words, all manual movements are transferred intoelectrical and thus not a totally manual machine.

Manual lathe machines are not powered via a computer control. Allactions are carried out by an operator. This is necessary in someinstances where certain procedures need to be carried out with humanjudgment and control. The chuck will still be powered by a motor, butspeeds and on/off power is controlled by the operator of machine. Thetool post movement is not created by a motor or computer at all. It isinitiated by a hand wheel which is physically turned by the operator andthus will create the desired resistance between the part and the cuttingtool.

The distinguishing factor of why the machine should be totally manualand not partially, is that the operator gets a feeling of resistance onthe hand wheels when there is no electrical assist. At times, it isnecessary to round off corners without cutting too deep into the surfaceof wheel. This becomes possible with a totally manual machine operatedby a skilled artisan.

Should this be tried on a CNC machine with hand wheels, no resistance isfelt and much deeper than desired cuts can be made that may damage thewheel rim beyond repair.

In a CNC machine, the movement of tool post and chuck are controlled bythe computer, thus the term computed numerical control. The computerwill command that power be supplied to motors in controlled amounts, torotate at given speeds via the control unit which gets feed back from anencoder attached to motor. With this information, the computer can nowtrack the updated location on the grid.

Thus, the computer will know where the tool post is located on the “X”and “Z” grid. In saying this the computer will also control speed ofrotation of chuck. So, if a pattern to follow or program is loaded onthe computer that has all this information stored, the computer now hasthe ability to complete the run with out any assistance from a human.

The combined CNC/manual lathe 10 provides several advantageous overconventional machines including, but not limited to: Saving job time—Ifa wheel is already on the machine, there is the possibility of doingsome repair work and then at the same time doing cosmetic work which isa time saver as set up time is reduced; Space—this machine willeliminate the need for two machines that require large floor area;energy consumption—the machine of the invention is built to have enoughpower to complete any wheel related job. A regular production machinethat is large enough for wheels will be an overkill on motor sizes etc.and will thus need much larger amounts of energy to complete the samejob on same wheel; Cost of equipment and setup—all costs will be reducedas machine is smaller, item specific and is two machines in one; Ease ofuse—the machine is built for one purpose, namely wheels. The programmingetc. is based on this as well as the size as are many other factors toonumerous too mention.

Machine 10 is Unique in Combining Axis Movement or Motion on theCNC/Manual Lathe:

The CNC/Manual combination lathe machine 10 of the present invention iscapable of doing full CNC work with movement created by either motors orhydraulics, but also has the ability to do fully manual controlledmovements created by the operator with hand wheels without anyelectrical assists. This is made possible in two different ways.

The first will be called multi level stacking of platforms. The secondis to enable rotation of one ball screw by two or more methods of powertransfer.

The first, with the aid of the multi level platforms that enablemovement on the same or different axis. An example of this is wherethere will be two or more separate platforms that will travel in thesame direction. In other words, there may be two or three platforms oftravel on the x axis alone. In this event the one platform will becontrolled by a motor (for CNC work). The second may be controlled by amanual hand wheel (for manual lathe), while a possible third level mayinclude hydraulics.

The bottom “Z” axis can in fact be thought of as an axis that can infact move the complete cnc machine forward and back as all the motorsetc will be on platforms that are on top of the bottom axis. This lowerplatform can thus bee totally free of any motors and can be totallymanual in all aspects as there is no electric or motors controlling it.It can either be manually moved or locked in place so as to allow theupper platforms to work. Movement on this can either be on a ball screwor a rack and gear.

The second method is by withdrawing the power from a motor that isenergizing a ball screw, the motor itself can now be manually turned.This could create a scenario where there may be a hand wheel on the oneend of a ball screw and on the other end a motor. Should the motor bepowered, it could turn the ball screw and if it were not, the hand wheelwould be able to turn the screw and thus turn the motor as well.

So therefore it can be said that movement of ball screw, rack, or leadscrew, can either be made with: A motor (electrically operated); theoperator turning a dial which will in turn, manually move the screw;hydraulic cylinders; or combinations thereof. The above can control theCNC and manual movement and use of the lathe, either independently or inconjunction with one another.

All of the above methods of motion can control the CNC and manualmethods of the lathe, either independently or in conjunction with oneanother. This will allow the combining of the two machines into one.

Machine 10 has a sturdy frame 7 that is built to accept linear rails asits guides. As the machine needs weight to provide stability, heavy dutysteel and also concrete are used in the construction of frame. Theweight is needed as when wheel spins there may be an imbalance caused asa result and weight in the machine itself will help in this regard.

Various methods can be used and at times could be a combination of theunder mentioned methods. Linear rails—For the most part linear rails andguides are used in the present invention. In applications involvingpolishing wherein particulate is created alternative rails or methods oftraverse may be used. Another method could be the dovetail and gib thatis commonly used on production machines.

Certain lock downs are necessary in the present invention. Theselockdowns will prevent any undesirable movements within any axis whenthe CNC part of machine is in action. The brake can lock down a manualaxis and disallow these movements. Various types of brakes whichnormally lock upon the linear rail are used. Alternatively, anyacceptable brake can be used. The two most common are pneumatic andmanual. Either of the two can be used. In the event of it beingpneumatic, then control of the unit will be initiated by the computer.If it were a manual then control would be by the operator of machine.

A gear box is used to create a similar direction of manual movement tothat of a conventional manual production lathe. This is done so as notto confuse the operator of machine that may have may have grownaccustomed to production machines. The gearbox can also have the abilityto disengage the hand wheel while under power of the motor on the otherend of the ball screw. This would occur when the CNC or computer iscontrolling machine. In this event the motor would turn the screw, butthe hand wheel would not turn. However, when power is released from themotor and the manual lathe is desired, the hand rail can be depressedback in toward the gearbox, thus engaging such so that hand wheel willnow in turn, turn the ball screw.

A CNC lathe will also often have hand wheels. Again the problem withthis, is that these wheels generate power to servo motors which createthe desired movement. The problem with this is there is no resistanceand no forgiving, when a move is initiated the tool will make that move,even if the wheel is in the way.

Method of Travel:

Motors—Preferably servo over stepper motors are normally used as theretravel is more constant and even, however in some cases where precisionis not as necessary eg. polishing, the less costly stepper motor can beused. The obvious differences between the two are the quality and thecost. For the most part however servo motors will be used.

The machine may use ball screws or lead screws. The main differencebetween ball screws and lead screws is again quality. The ball screw ismore precise than the lead screw. There is a difference in cost.Although the lead screws are far better in quality than was in the past,it is still desired to use the ball screw. Future improvements in thequality of the lead screws, may allow cost effective use in the future.The desired screw will have zero backlash when used in the machine.

When the ball screw turns, the nut on the screw will traverse the lengthof thread. This nut is attached to a upper platform and thus theplatform will move as screw rotates.

A large motor 61 located within the frame of the machine will rotate thechuck 50 and wheel rim 11 via a spindle or shaft 52 with either a director belt driven system. An electrical brake is used to rapidly deceleratethe speed. The brake is a series of resistors or capacitors.

Unlike a universal machine that was built for many differing jobs thatwill need a larger motor to be able to have enough torque to completeany application, machine motor can be large enough to complete aspecific job and thus be sized accordingly.

With the use of an inverter that can create three phase power with asingle phase input, there will be many options available. So there cannow be the possibility of using single phase power to run entiremachine. This is an advantage as now machine owners will not require 3phase power. Also an advantage that power consumption will be lower thanmost other machines.

Computer 8 operates the CNC (computed numerical control). It is theintelligence in the machine, that makes normally complicated procedures,far simpler. There are various methods that these apparatus can beattached to the machine and the sole difference in all methods are whatis comfortable for that particular machine operator. Installed on thissystem is the program, which will be discussed in further detail in thenext few paragraphs.

As the machine can be connected to the internet, it becomes possible touse communication programs like Skype. This can allow the operator ofmachine to work on machine whilst getting guidance from an outsideparty, possibly in another country. Video and audio are possible asmachine has video camera and headset.

The machine shall have an enclosure over the body that shall disallowobjects to fly from within and cause possible injury to those onoutside. The probable objects that may be projected is the wheel itself,however other items such as chuck keys etc could also be catapulted. Thedoor of enclosure may for safety sake have a micro switch that will notallow the chuck to turn on, if door is not closed. The lighting withinenclosure shall be bright and extend for the length of the inner chamberso that it will still be possible to see within the back and inside ofthe wheel. This will enable the operator to read for possible reference,numbers that are stamped within the wheel while it is mounted on chuck.

The tool post has a quick release method by rotating the lever on thetop of the unit, a cam is released and the tool can slide out. Thismakes changing of tools and probes etc. both quick and easy. Angle oftool and positioning to wheel and within machine is also easy to adjustby loosening top nut and aligning or moving the post itself.

The running program can be made up in two different ways, but either waywill essentially perform the same functions.

The first way is by building a specific dedicated program that is madefrom scratch from the ground up for the purpose of doing wheels. Therewill be no need for another program as this will perform what is neededto function with working on wheels.

The second will be an overlay of an existing off the shelf program. Inother words, screens and buttons and functions will be in the form of aconversational overlay that will generate commands to an existing offthe shelf program.

In both of the above scenarios there will be an operating system, whichcould be one of many. To some degree, should the second scenario of anof the shelf program with an overlay be used, then some other parts,other than wheels, may be able to be worked upon. The method of doingsuch work would be to open the off the shelf machining program and notthe overlay. By doing this the machine can in fact still perform as aregular cnc lathe and thus be capable of working on parts other thanwheels.

There are many smaller, but significant tasks that the new program willperform. They are digitizing the wheel and then being able to finish thewheel by cutting or polishing.

There are certain events that it may be in the interest of the seller orbuilder and also the owner or purchaser of this machine that may make itadvantageous to have a series of codes, that will either lock, or keepunlocked and functioning, the machines program and many of itsabilities.

The program itself is wheel specific and will simplify an otherwisecomplicated procedure which would require a higher level of training. Itwill also eliminate many of the mistakes that can be made when doingwheels on an of the shelf program.

Digitizing a wheel is mapping the shape of the top portion or face of awheel.

The probing or digitizing method of measurement should be accuratewithin approximately 0.001″ (0.03 mm). However there is built into theprogram a smoothing action that will average out readings taken to allowa smoother more even looking cut.

There are various methods this can be done and with various probes ordigitizers. An uncommon method will be to digitize the wheel on a standwith a wheel locator (Wheel Cones) whilst using a digitizing arm. theshape of the face of the wheel is followed while taking readings.

The probe, with the ability of the machines movements within its axis,will move up to the wheel, touch and let computer read where did so onthe xz grid. Then it will move back a small amount, move sideways asmall set amount, go forward again and take another reading. And so ontill end of wheel. This is then stored as a file on the computer 8 andwill be available as a map of the face of the wheel rim 11 for futureuse.

The reason for cutting the face of the wheel is many new wheels have amachined face from the factory and this often gets damaged during normaluse. The idea is to be able to re create this same finish so thatoriginal look can be restored. If a wheel rim 11 has been previouslydigitized or probed, then that file can be opened. The cutting of thewheel face is done by following that same pattern of that same wheelthat was originally digitized. In following this pattern, one now hasthe ability to place a tool in the area on the axis grid that will beable to trim or polish the surface of the wheel.

In doing this, with a very light trim, all blemishes can be removed andthus the wheel can have a new appearance. There are other tool typesthat can be used like polishing wheels.

When the start button is pushed, a user will be prompted to save wheeldetails in data base. The data base will give a user various fields fordata entry and this will be the operators choice on what to complete. Apicture of wheel can now be taken with on board camera. A User will nowbe prompted to goto start position of wheel, which is the position wherea user would want to start cutting the wheel. A user will press the okbutton which lets computer know to take that positional reading and saveit and then automatically will move the probe away from wheel to a safeposition. The computer will now prompt a user to goto the end position,which is where a user would want the last point of contact for cuttingto be. Once at that position a user now hit the ok button which againlets the computer take that positional reading and saves it.

The machine will now automatically retract (Z+) the probe to a safeposition.

Then would go toward the start point that was originally saved. As probetouches the start point previously recorded, it stops. Machine nowretracts (Z+) probe by an amount that can be changed numerically via thekeyboard normally about 0.020″.

Now machine would move over (X−) also by a pre set amount and aftermoving over would again move forward toward wheel and when touches wouldstop and again take a reading. I would then move out and slowly work itsway across wheel towards the position originally recorded as the end.

When probe gets to the end position, it will then move back on the (Z+)until its clear and safe. The probe cycle is now complete.

In saying this there is also a “retract” button on the monitor screensthat will give a user the option of allowing the computer to safelyretract the tool or probe.

The “PAUSE” button has a purpose and that is when button pressed, itwill pause the probe in the away from wheel position. This is so thatthe wheel can be turned to another position, while the probe is nottouching it. The reason for this is that the probe has to follow astraight line from beginning to end of the probe cycle and on somewheels the spokes are curved and wheel has to be turned.

The “FINE, MEDIUM and COARSE” buttons do in fact what they say. Theprobing can be done in fine, medium or coarse. In the event that thereis a lot of detail on a section of a wheel, a user may need to probe onfine. Fine probing is more precise but takes more time, so normally onlysmaller areas of this are done where needed. The differentiating factorbetween the three buttons is in fact the distance between probe hits onthe surface of the wheel. The distance can be changed numerically onscreen with keyboard. One can swap between the buttons whilst in acycle. In an area of wheel rim 11 that needs fine, this can be done. Inan area that can do with coarse or medium, the operator can hit thebutton and it will automatically change the distance between the probehits on the surface of the wheel.

The program has built in capabilities that will allow various proceduresto take place. Some of these will be cloaked (hidden) and some will beinitiated by the operator of machine.

Smoothing action is a method of taking all the points that were probedand creating an average pattern within them. The problem with that is ina in areas of probing that have tight turns and radiuses, the smoothingwill occur there too. This would make the smoothing action detrimentalin that specific case. However what I′ve done here is that a user can bearea specific on where a user want the smoothing to occur.

Last cut memory is a method of going a little deeper in a specific areaon a wheel that has already been digitized. It is undesirable to weld onthe face of a wheel as it discolors the surface and does not look goodon a finished product. Should there be a gouge on the surface that is inan area that is thick enough to cut a slightly deeper area, this can nowbe done and still cut original depth in areas that cannot go deeper.

Using the “Cut In” “Cut Out” “Cut More” “Cut Less” and whilst the wheelis turning and performing a cut, a user will press these buttons, one ata time, which will move the tool in direction requested, by a user preentered amount, one click at a time. This will then allow a user to takemore or less of certain areas of the wheel.

However doing this may or may not leave fine lines as buttons arepressed. At the end of the cut a user will be prompted with an option ifa user want to use same pattern a user just created again. If sosmoothing will be done thereon and another cut can be made, but with nolines. There is another way of manually doing this, however wont be asaccurate. Whilst a wheel is being cut, a user can manually move themachine by hand with the hand wheels and create the same result. Howevershould a user need to go a bit deeper in another cut, there will be nomemory to do this.

Data base is extremely user friendly with as much detail as a user want.As much info on that specific wheel that was saved can be entered when,or after it was digitized. Including a photograph by on board camera.

Next cut adjustments are made after each cut by pressing the relevantbuttons in direction desired. This will move the position of tool fornext cut as instructed. No numerical positional values have to beentered as would be on a regular production CNC lathe.

Firstly, the file for that particular wheel is loaded. Then check thatthe data and or picture is the same. Press the “START” button and thecomputer will prompt a user to set tool to the start position and pressOK. Once OK is pressed, the machine will now record that position as thesame as when the start position of the probing of that wheel wasrecorded.

The “DRY RUN” button can be used to see if the file loaded is firstlycorrect and also to fine tune the positional settings of start location.During a dry run the spindle will not turn so position can be closelymonitored. The direction and speed of travel can be controlled with athe likes of an electronic hand wheel eg. the finger wheel on a computermouse.

To move that start position, the “cut more/less and in and out buttonsarrow style buttons can be used. what it in fact does is loosens up thestart position and the resets all values as to how much the operator hasshifted such start. This will then allow the operator to cut more orless in certain areas of wheel. These values are normally set after eachfull pass so one can see where more needs to be cut.

Normally when working on this machined finished face, if there is agouge on the working area, a problem is created. If the scrape iswelded, the weld would normally be seen once the wheel is cut, as it isalmost always different in color. If the gouge is in an area that thewheel is thick enough to cut off a little extra, then welding may not benecessary. However the problem that would normally occur is that if auser cut deeper in one part of the wheel, then all other areas will needto be cut to same depth. The computer will now allow a user to use the“in out and more and less buttons” whilst doing a pass. In other words,one can start off doing a normal pass and then while blade is gettingtoward area of concern, the deeper button can be clicked, one at a time,which will in turn take the blade in the direction requested at the preentered value for that block. Once finished with that pass a user willbe prompted: “does user want to follow the original file path or the newone a user created”. Now if a user follow new path the machine willfollow said path but with new values as and when a user entered them onprevious run.

Another method of doing the same action to eliminate the need for manyundesirable welds, will be to graphic part of the program here the mapof wheel can be seen on either the cutting or probing screen and pulland drag the line according to where a user would like them to be.

Yet another method will be to combine the manual part of the machinewith the CNC part during a CNC cutting cycle. As there are levels withinthe stack of platforms and axis, there is normally one level on the xand on the z that are controlled only by manual movements. In sayingthis whilst a run on the cnc is in progress, very gently one can movethe manual platform method of traverse in the desired direction. Thiswould create a blending effect whilst cutting deeper in desired areas.This could obviously be done as well between runs but then the desiredblending will not occur. While the CNC part of machine is working usingthe combined x and z axis movements to follow shape of wheel, theoperator will have the ability to move all the whole CNC part of machinein and out on the z axis. This will allow one to do a light cut in areasof the wheel where this is desired and also a medium to heavy cut inother parts.

This will enable deeper gouges to be cut out of wheels where this isnecessary and in turn not taking excessive amount of metal off of thewheel.

This method of cutting a wheel is far superior than regular off theshelf programs as in a regular CNC program the operator has tocontinually enter values after every completed movement during the wheelcutting cycle. Should a value be mistyped or incorrectly calculated byoperator, the machine could be mistakenly set up in a way that willprobably damage the wheel and possibly the machine and operator.

The lathe will have the ability to be able to be used in either themanual mode, or the CNC mode. This would be beneficial to wheelcompanies as often two lathes are needed to serve this purpose and inthis case, one will be sufficient.

The movement described below is that of the apron itself, on top ofwhich is the tool post. It is not in fact the rotation of the spindle.

Whereas some cnc (computer controlled) machines do have the ability tocontrol movement manually with either a dial or jog button, thismovement is created by the operator turning a dial, which in turn willsupply power to electrical motors that will create movement of toolpost.

The problem in using computer or electrically controlled movement forthis purpose of manual motion, is that the operator has no personal feelof resistance to the movement of the tool post and a deeper than desiredcut can easily be made.

In other words should an operator turn dial slightly too much, thismovement is created and executed immediately with no forgiving.

On standard manual lathes that are not computer controlled, thismovement is created by an operator turning a handle which will in turncreate movement of tool post. Resistance is felt by operator thusreducing the risk of an error. Resistance is the key

With this in mind the “automotive wheel combo lathe” will have theability to be used as a conventional manual machine, as the applicablemotors can be turned off and a manual operator controlled method ofmovement can be used.

When the “MANUAL” button mode is used, the servo motors will move thetool post to a desirable position for manual work and then they wouldswitch off which would allow manual movement of ball screws. This wouldallow the operator of machine to then manually control the position oftool post, while still being able to turn on the spindle which will inturn spin the wheel.

In doing this, the complete method of a manually controlled machine thathas no cnc or servo motor assists is created. Furthermore, at the touchof a button the machine can go back to a cnc machine with the fullability of computer controlled movement. Also due to the fact that thismachine has stacked levels of axis as described in beginning ofdocument, there will be certain levels that will only be controlled bymanual movement.

The manual mode is for wheels that have suffered some physical damage.It would allow the operator to manually control certain settings on thelathe. These settings would include speed of turret and positioning ofthe tool post within the x and z axis by a manual movement of a handwheel without the use of positional electrical motors. An example wherethis would be used would be on a wheel that needs to be skimmed. Thiswould be necessary when the wheel plate that makes contact with the hubof the motor vehicle may have a burr that needs to be corrected. Alsowhen a wheel is chrome plated this often happens as the chrome may bethicker, or have left some burrs that may cause run out when the wheelspins. There are many instances that will require a manual lathe tocorrect damage on a wheel

In this case the operator can control the machine in the manual mode (ashe would any manual machine). There are other times that a wheelwright(repairer of wheels) would require a manual lathe for the repair, orpartial repair of a wheel. This could all be done in the “manual mode”.

The lathe will have the ability to be able to be used in either themanual mode, or the CNC mode. This would be beneficial to wheelcompanies as often two lathes are needed to serve this purpose and inthis case, one will be sufficient.

The movement described below is that of the apron itself, on top ofwhich is the tool post. It is not in fact the rotation of the spindle.

Whereas some cnc (computer controlled) machines do have the ability tocontrol movement manually with either a dial or jog button, thismovement is created by the operator turning a dial, which in turn willsupply power to electrical motors that will create movement of toolpost. The problem in using computer or electrically controlled movementfor this purpose of manual motion, is that the operator has no personalfeel of resistance to the movement of the tool post and a deeper thandesired cut can easily be made.

In other words should an operator turn dial slightly too much, thismovement is created and executed immediately with no forgiving.

On standard manual lathes that are not computer controlled, thismovement is created by an operator turning a handle which will in turncreate movement of tool post. Resistance is felt by operator thusreducing the risk of an error. With this in mind the “automotive wheelcnc lathe” will have the ability to be used as a conventional manualmachine, as the applicable motors can be turned off and an operatormethod of movement can be used.

The program is windows compatible and thus can carry out its ownfunctions, but also be able to allow windows operating system to work inconjunction with it. External monitoring of files and system, includingvideo and photography can be achieved.

Downloading and uploading will be allowed by known parties.

With this in mind the above will create various settings wherein manypositive features can be created. Some are: Photos of wheels in database; remote training on machine; video conferencing with includedcamera; external diagnosing and correction of break downs; andDownloading of Upgrades.

The program will be able to carry out certain functions normally notincluded in cnc lathe abilities. It will have the ability to create astart and end position of motion for each wheel that is digitized.Before, after and within that movement it will have the ability toperform certain functions. There will be a lead in and out that ispreset and can be changed by operator. This is so as to not leave avisible start or end point on the wheel.

It will have the ability to create its own smoothing action that can becan be targeted to a certain part or all of the digitized map of thewheel.

It will have the ability to manually override the program and createmovements controlled by operator whilst and during a run in the cuttingprocess of a wheel. This can be used should there be an area on face ofwheel that has a possible burr or damage and there is a desire to deepenor withdraw the depth of the movement in that specific area. A memory oflast cut is made and operator can either follow the last cut or theoriginal.

Upon a wheel being digitized, it is now possible to take the points thatwere recorded in that file and create a smoothing action by averagingthem out. When a wheel is being probed or digitized, some of thereadings may be ever so slightly read in error. There are many possiblecauses that this may occur. For the most part there is normally still alayer of clear coated paint over wheel. Within this covering there maybe slightly high spots due to foreign object such as dust that fell ontowheel while paint was curing. Should the probe have taken a reading atthe point where the dust had caused a high point, this reading wouldappear in the new probed file to be saved. There are many other factorsthat could cause this problem. Another possibility is when there is awheel that needs to be turned during a probing cycle, there may a heightdifference from one spoke to another. The reason that some wheels needto be turned is that there is no straight line from the probing startpoint to the end. The desired area of digitizing is the face of thewheel (high areas) and not going into lug holes and low areas of wheel.Remembering that we are only skimming the face of the wheel.

There is no straight path from start to end of digitizing or probingpath. In this event the wheel would be turned once pause is activatedduring the probe cycle, so as to allow the continuation of the straightline for probe to follow.

On some wheels there is a steep incline at the beginning of the cut, asthere is also at the end of the cut. This creates a problem as mostcutting tools need to be set at an angle to facilitate the direction andpositioning of the movement. In other words the angle of tool may allowthe first part of wheel to be cut, but cannot move over the last inclineon wheel on the path at end of cut. In the past it has been necessary toinitiate two separate procedures or cuts to complete wheel.

Also, in the past, the area of contact of the wheel and cutting toolconstantly varies during a move as the shape or pattern of the wheelwould constantly be varying. This may lead to problems both in thequality and appearance of the end product.

The new machine has a method around this issue. It is in fact arevolving turret or tool post. The angle that is set at the beginning ofa procedure will automatically with the aid of the computer to keep anoptimal cutting angle at all times.

There is also the possibility of polishing wheels with a buffer or pad.Instead of using a tool with blade, a motorized polishing buff can bemounted in its place. In this event the wheel would still be digitizedso as to allow machine to follow that pattern and then polishing couldbe attained though the cnc machine. What in fact would be happening iswhile the pattern of the wheel is being followed, a buffing wheel willbe spinning and just touching on the surface of the wheel. While this ishappening the machine will be turning the wheel, either at a preset highor low speed.

The computer will also allow the tool post (where upon the buffing wheelwill be set) to move backward on the “Z” axis to touch on a block ofpolishing compound, or to be oiled with polishing oil via the serpentineoiler.

While the machine is following the pattern of the wheel as it would bewhile cutting a wheel. instead of mounting a cutting tool in the toolpost, a polishing buff will be mounted instead. This will allow apolished finish to be attained but only on the first flat surface of thewheel. This is finish on many oem wheels and up to now cold not beeasily duplicated in a used wheel refinishing plant.

Up to now most chuck jaw 51s that were made for wheels have steps inthem that will wrap around the lip of wheel so as to fasten the wheel tomachine. At times when using a manual (not cnc) lathe, the wheel ismounted with the face facing the chuck so as to be able to get to workon the back or inside of the wheel. This is not always possible as manywheels have a face that is convex and some also have spokes and otherhindrances that get in the way of fastening the wheel in a suitableposition that will allow the wheel to spin central to the chuck ofmachine. (See fig? below). The new machine can offset the depth thatwheel fits into the jaw 51 51 with the aid of a set screw that can beadjusted to suite wheel.

The new method off attaching a wheel within jaw 51 that can compensatefor the above will be as follows. There will be placed within the jaw51, at the contact area where face of wheel will be situated, a setscrew that can offset the depth that wheel fits into the jaw 51 51 andthus the angle of the wheel can now be adjusted.

Motion can also be created with the use of hydraulics. This canfacilitate with polishing to keep buffer steady. The positive aspects ofusing hydraulics at times over motors is that it can take more abuse andcertain applications do abuse machine more that others. An example ofthis is polishing. There is most certainly a lot of stress and not tomention dirt that can affect the machine adversely. Should theapplication of the machine be aimed more at polishing as a n example,then it may make sense to use either all or partly hydraulic means toattain the best level of workmanship.

Much the same as the above polishing, but instead of a buff wheel, adrill will be placed in the tool post. This will allow holes to bedrilled at specific predetermined positions in the wheel. An example ofthis is a BMW wheel will have a different PCD (pitch circle diameter) tothat of a Mercedes. The PCD is in fact the bolt holes in wheel to whicha bolt is placed through that will attach the wheel to the car.

With this machine, as it has the capabilities of determining positionsit will have the possibility of drilling holes at these positions

With a wheel in place on machine and determined central, it would bepossible to attach a drilling or milling method to tool post which willfacilitate the drilling out of bolt holes at given distances from centerof wheel. This would be in place of either the cutting blade or thepolishing motor.

The CNC part of the lathe will be able to determine at what distance adrill is from the center. Thus if it is at 50 mm from center, the PCD itwould be drilling would be 100 mm as we are working on circle diameter.Now there is in place an encoder on the spindle motor (chuck) of thelathe. This normally serves as a means of controlling the rotation andspeed of the wheel. It is however very accurate in determining where itsposition is within a single revolution. The computer control can thussplit a revolution into as many quadrants as there are lug holes in awheel. Holes are drilled in wheel 11 at a position determined by thedistance the “X” axis is from the center of wheel 11. The method ofactual drilling would be the “Z” axis moving inward with drill and thusboring of hole will occur.

The same cycle will continue but with the wheel being rotated to thenext quadrant at which another hole will be drilled.

The above method can either be carried out manually by using the DRO(Digital Read out) or by using the control of the computer.

There are many instances where this machine will improve quality ofworkmanship, time management and make it a more affordable investment ona whole than it has been in the past with similar machines.

There are a few reasons that one may need to use this machine tocomplete a wheel repair or refinish. In either event the following stepswill be followed:

Mount wheel 11 in jaw 51 of chuck; if wheel 11 is not running central inchuck, then adjust at least one of set screws 73 for positioning ofwheel; If wheel is to be cut manually then press manual operation buttonon display and proceed to cut in manual mode; If wheel has a saveddigitized file then proceed to cut wheel in CNC mode; If wheel is to bedigitized or probed then press digitize wheel and follow the on screenprompts; after wheel is digitized, load the applicable digitized filefor cutting wheel; start wheel cut process in CNC by performing a dryrun, while watching following distance of tool to see if all in orderbefore the final cut; after all settings are concluded and ready for cutpress start; after this run when wheel stops, visually look at wheel tosee where adjustments are necessary, for next cut. Complete this step asnecessary until wheel is completed.

The jaw 51 that can adjust the wheel to better centralized position inchuck.

The program and its method in making work to be carried out simpler withless chance of mistakes.

A safer method of doing wheels for both the user of machine, the wheeland the machine itself. This is attained by the physical enclosurearound wheel and the workings of actual machine and program. The smallfoot print with large wheel capabilities.

It is exceptionally hard to get a production lathe that is small and hasa large swing. More so with wheels as the sizes have increasedconsiderably over the past decade. As the machine has a small foot printthe space rental for the work area is reduced to that of a largemachine. Also many existing shops have lathes today that cannot work onthe larger wheels.

For the most part there has been no real reason to incorporate themanual and CNC lathe into a single unit. With wheels there is a need forboth machines and due to floor area rental and also cost of machine, itmakes sense to incorporate both manual and the cnc method.

In the novel machine 10 there is no disconnect between motors to createits manual movement. Also a CNC program can be run at same time as, andin conjunction with the manual part of the machine.

The below description is of a significant reason that CNC and totallymanual machines are not combined. Manual is referring to is manual“without servo motor assistance”. The reason that the user does not wantthe manual without motor assistance (i.e. electrical movement) is thatwe need to be able to feel pressure exerted whilst we are cutting awheel. If one cannot have this feel, far deeper cuts and mistakes willbe made while moving an electrical hand wheel manually that has no feelat all.

On a normal CNC machine, on a regular basis (probably every time machineis switched on) a homing action is needed. This is for the control ofmachine to know its own location within its axis. Homing occurs wheneach of the applicable axis movements touch up against a pre determinedlimit switch and inadvertently creates a home position that the machinewill work from. This will aid in tool setting distances and create auniform and constant environment from which the machine will operate.Now most CNC machines have a manual ability which is essentially just anoverride of control of machine. This movement is often created byelectrical hand wheels. As described in paragraph above, this is not themanual ability that we are seeking as there is no feel for what we aredoing. What is wanted is total manual movement created by a source otherthan the electrical control of machine. We need to manually turn ballscrews or gear racks to create this movement. Unfortunately once this isdone on a conventional CNC, positions are lost.

In the case of the novel combined manual/CNC machine, homing is notnecessary as it is easier to setup the angle of the tool at the startposition of the wheel to be cut, and then setting this in the machinecontrol as the start position by pressing a button on the computerscreen. This will be set on every wheel as on average, every wheel willbe different.

On a normal CNC, if it were to have the manual ability, its own homingposition will be lost every time one moves the manual position of themachine. This would create a lot of extra work between every job. Itwould not be desirable on a day to day CNC machine to have manualcapabilities, that are not controlled by the control itself.

On the novel machine, there is no problems with moving the manualposition of the machine as there is no homing and setting position ofeach wheel is done anyway and is a very easy process.

Another advantage in the way that the novel CNC/manual machine is set upis that the CNC and the manual ability of the machine can be operatedsimultaneously. This is handy when there would be a deep scratch in thewheel and while the CNC program to cut the wheel is running, and withwheel spinning, a slight adjustment in the manual z table can beperformed whilst the blade or tool is passing over the scratched area.This would allow minimal metal removal from the wheel as a deeper cut isonly performed in the area where it is needed.

When renting space to open shop, a key factor is power into building.This is a limitation in many cases if there is no 3 phase power. It iscostly and inconvenient to work around. This machine can be used onsingle phase power if necessary and also the electrical consumption iskept to a minimum as all motors etc are geared for the job at hand.

With a conventional lathe production machine, it is always an overkillas at time of manufacture there is no way of them knowing exactly theuse of the end user.

It is also an option that part of the machine can be separated at FIG.1.81 upwards and sold in a kit form. This could be attached to almostany lathe. The kit would come complete with FIG. 1.81 and above and willinclude a separate box with computer and control.

While the invention has been described in its preferred form orembodiment with some degree of particularity, it is understood that thisdescription has been given only by way of example and that numerouschanges in the details of construction, fabrication, and use, includingthe combination and arrangement of parts, may be made without departingfrom the spirit and scope of the invention.

1. A machine for refinishing of repairing of damaged wheel rimscomprising: selective operability as a manual lathe, CNC lathe, orcombinations thereof; a rotational wheel rim holding spindle; a jaw forholding a wheel rim, said jaw having plurality of angular surfacefeatures that further secure said wheel rim; set screws imbedded in saidjaw, wherein said set screws extend outward from an interior channelformed in said jaw and are utilized to level a wheel rim held in saidjaw; at least two platforms for supporting a tool post; wherein saidtool post is movable along at least 2 of an x-axis, a y-axis, and az-axis.
 2. The machine of claim 1 wherein said spindle is rotatable bymoving a wheel rim secured thereto.
 3. The machine of claim 1 whereinsaid tool post is rotational about on an axis.
 4. The machine of claim 1wherein said tool post is moved manually, by a computer controlledprogram, or combinations thereof.
 5. The machine of claim 1 furthercomprising of a large swing about the spindle relative to size of amachine frame.
 6. The machine of claim 1 wherein said selectiveoperability is performed while said wheel rim remains in said spindle.